COMPRESSOR (for 2GR-FE) INSTALLATION

INSTALL RADIATOR ASSEMBLY

1. 

   Install the fan shroud with fan motors to the radiator assembly with the 2 bolts.

   11 N*m

   112 kgf*cm

   8 ft.*lbf

2. 

   w/o Air cooled oil cooler:

   Table 1. Text in Illustration

   *1

   Matchmark

   
   

   1. Align the matchmark as shown in the illustration. Connect the 2 oil cooler hoses.

   2. Install the oil cooler pipe with the 3 bolts.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

3. 

   w/ Air cooled oil cooler:

   Table 2. Text in Illustration

   *1

   Matchmark

   
   

   1. Align the matchmark as shown in the illustration. Connect the 2 oil cooler hoses.

   2. Install the oil cooler pipe with the 3 bolts.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

4. 

   Install the 2 lower radiator supports.

5. Install the radiator with fan shroud and fan motors.

6. 

   Connect the suction hose to the hose clamp.

INSTALL COOLER CONDENSER ASSEMBLY

1. 

   Install the cooler condenser assembly as shown in the illustration.

   Tip:

   If the condenser is replaced with a new one, add compressor oil to the new condenser.

   Capacity
   40 cc (1.35 fl.oz.)

   Compressor oil
   ND-8 or equivalent

INSTALL NO. 2 FAN SHROUD

1. 

   Install the No. 2 fan shroud with the 2 bolts and 2 claws.

   11 N*m

   112 kgf*cm

   8 ft.*lbf

INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY

1. Install the 2 radiator support cushions.

2. 

   Install the upper radiator support sub-assembly with the 4 bolts.

   30 N*m

   306 kgf*cm

   22 ft.*lbf

3. 

   Connect the 6 wire harness clamps.

4. 

   Connect the 2 cooling fan ECU connectors and 2 clamps.

CONNECT NO. 1 WATER BY-PASS PIPE

1. 

   Install the No. 1 water by-pass pipe with the 2 bolts.

   12 N*m

   122 kgf*cm

   9 ft.*lbf

2. 

   Install the No. 1 cooler refrigerant suction hose with the bolt.

   9.8 N*m

   100 kgf*cm

   87 in.*lbf

3. 

   Connect the No. 3 water by-pass hose.

CONNECT NO. 2 WATER BY-PASS HOSE

1. 

   Connect the No. 2 water by-pass hose.

CONNECT OIL COOLER HOSE

1. 

   Align the matchmarks as shown in the illustration. Connect the 2 oil cooler hoses.

   Table 3. Text in Illustration

   *1

   Matchmark

CONNECT NO. 2 RADIATOR HOSE

1. 

   Connect the No. 2 radiator hose.

CONNECT NO. 1 RADIATOR HOSE

1. 

   Connect the No. 1 radiator hose and hose clamp.

INSTALL HOOD LOCK SUPPORT BRACE SUB-ASSEMBLY

1. 

   Install the hood lock support brace sub-assembly with the 2 bolts.

   8.5 N*m

   87 kgf*cm

   75 in.*lbf

2. 

   Connect the 4 connectors.

3. Connect the 5 wire harness clamps.

INSTALL NO. 2 FRONT BUMPER SIDE SEAL RH (for ALPHARD)

1. 

   Install the No. 2 front bumper side seal RH with the 2 clips.

INSTALL NO. 2 FRONT BUMPER SIDE SEAL RH (for VELLFIRE)

1. 

   Install the No. 2 front bumper side seal RH with the 2 clips.

INSTALL NO. 2 FRONT BUMPER SIDE SEAL LH (for ALPHARD)

1. 

   Install the No. 2 front bumper side seal LH with the 2 clips.

INSTALL NO. 2 FRONT BUMPER SIDE SEAL LH (for VELLFIRE)

1. 

   Install the No. 2 front bumper side seal LH with the 2 clips.

INSTALL NO. 1 AIR CLEANER INLET

1. 

   Install the No. 1 air cleaner inlet with the bolt.

   8.0 N*m

   82 kgf*cm

   71 in.*lbf

INSTALL HOOD LOCK ASSEMBLY (for LHD)

1. w/o Engine Hood Courtesy Switch:

   
   
   1. 

      Apply MP grease to the sliding areas of the lock.

   2. 

      Connect the hood lock control cable.

   3. 

      Install the hood lock assembly with the 3 bolts.

      7.5 N*m

      77 kgf*cm

      66 in.*lbf

2. w/ Engine Hood Courtesy Switch:

   
   
   1. 

      Apply MP grease to the sliding areas of the lock.

   2. 

      Connect the hood lock control cable.

   3. 

      Install the hood lock assembly with the 3 bolts.

      7.5 N*m

      77 kgf*cm

      66 in.*lbf

   4. 

      Connect the connector.

INSTALL HOOD LOCK ASSEMBLY (for RHD)

1. for ALPHARD:

   
   
   1. 

      Apply MP grease to the sliding areas of the lock.

   2. 

      Connect the hood lock control cable.

   3. 

      Install the hood lock assembly with the 3 bolts.

      7.5 N*m

      77 kgf*cm

      66 in.*lbf

2. for VELLFIRE:

   
   
   1. 

      Apply MP grease to the sliding areas of the lock.

   2. 

      Connect the hood lock control cable.

   3. 

      Install the hood lock assembly with the 3 bolts.

      7.5 N*m

      77 kgf*cm

      66 in.*lbf

INSTALL BATTERY

1. Install the battery, battery insulator and battery tray.

2. 

   Install the battery clamp with the bolt and nut.

   Bolt
   46 N*m	469 kgf*cm	34 ft.*lbf
   Nut
   4.9 N*m	50 kgf*cm	43 in.*lbf

3. Connect the positive (+) cable to the battery positive (+) terminal.

   7.6 N*m

   77 kgf*cm

   67 in.*lbf

4. Connect the 2 wire clamps.

CONNECT COOLER REFRIGERANT LIQUID PIPE A

1. Remove the attached vinyl tape from the tube and the connecting part of the cooler condenser assembly.

2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the tube joint.

   Compressor oil
   ND-OIL 8 or equivalent

3. Install the O-ring on the cooler refrigerant liquid pipe A.

   Note:

   Keep the O-rings and O-ring fitting surfaces clean from dirt or any foreign objects.

4. Install the cooler refrigerant liquid pipe A on the cooler condenser assembly with the bolt.

   5.4 N*m

   55 kgf*cm

   48 in.*lbf

CONNECT NO. 3 AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

1. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly.

2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.

   Compressor oil
   ND-OIL 8 or equivalent

3. Install the O-ring on the No. 3 air conditioning tube and accessory assembly.

   Note:

   Keep the O-rings and O-ring fitting surfaces clean from dirt or any foreign objects.

4. Install the No. 3 air conditioning tube and accessory assembly on the cooler condenser assembly with the bolt.

   5.4 N*m

   55 kgf*cm

   48 in.*lbf

INSTALL V-RIBBED BELT

1. 

   Install the V-ribbed belt.

2. If it is difficult to install the V-ribbed belt, perform the following procedure:

   
   

   1. Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration.

   2. Release the V-ribbed belt tension by turning the V-ribbed belt tensioner counterclockwise, and put the V-ribbed belt on the tensioner pulley.

      Note:
      

      • Put the backside of the V-ribbed belt on the V-ribbed belt tensioner pulley and idler pulley.

      • Check that the V-ribbed belt is properly set to each pulley.

3. 

   Turn the V-ribbed belt tensioner counterclockwise and remove a 5 mm bi-hexagon wrench.

4. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Tighten the cylinder block drain cock plug (for Bank 1).

   13 N*m

   130 kgf*cm

   9 ft.*lbf

3. Tighten the cylinder block drain cock plug (for Bank 2, w/ Cylinder Block Drain Cock Plug).

   13 N*m

   130 kgf*cm

   9 ft.*lbf

4. Loosen the air drain cock plug.

5. Add engine coolant.

   Standard Capacity
   10.6 liters (11.2 US qts, 9.3 Imp.qts)

   Note:

   Do not substitute plain water for engine coolant.

   Tip:
   

   • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

   • Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

     If the engine coolant level is low, add engine coolant.

6. Add engine coolant to the radiator reserve tank until engine coolant overflows from the air drain cock plug hole. Then tighten the air drain cock plug.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

7. 

   Continue adding engine coolant until it reaches the B line. (*1)

   Table 4. Text in Illustration

   *a

   B Line

8. Install the reserve tank cap. (*2)

9. Run the engine at about 2000 rpm to warm it up until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes. (*3)

   CAUTION:
   
   

   • Wear protective gloves.

   • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

   • Keep your hands away from the fan and No. 2 fan.

   Note:
   

   • If the radiator reserve tank runs out of engine coolant just after the engine is started, stop the engine immediately, wait until the engine coolant has cooled down, and then add engine coolant.

   • Make sure that the radiator reserve tank still has some engine coolant in it.

   • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

   • If there is not enough engine coolant, the engine may overheat or be seriously damaged.

   Tip:
   

   • 

     If engine coolant comes out from the port connected to the radiator reserve tank, the thermostat has been opened.

     Table 5. Text in Illustration

     *a

     Port

   • After the thermostat has opened, idle the engine until the engine coolant in the radiator reserve tank goes from being cloudy to a clear red.

10. Stop the engine and wait until the engine coolant cools down. (*4)

11. 

    Check that the engine coolant level is between the full line and low line. (*5)

    Table 6. Text in Illustration

    *a	Full Line
    *b	Low Line

    Tip:
    

    • If the engine coolant level is below the low line, remove the reserve tank cap and repeat steps from (*1) to (*5).

    • If the engine coolant level is above the full line, drain engine coolant so that the engine coolant level is between the full line and low line.

CHARGE WITH REFRIGERANT

1. Perform vacuum purging using a vacuum pump.

2. 

   Charge with refrigerant HFC-134a (R134a).

   w/o No. 2 Air Conditioning Tube
   780 to 880 g (27.5 to 31.0 oz.)
   w/ No. 2 Air Conditioning Tube
   700 to 800 g (24.7 to 28.2 oz.)

   09985-20010

   09985-02130

   09985-02150

   09985-02090

   09985-02110

   09985-02010

   09985-02050

   09985-02060

   09985-02070

   09985-02140

   09985-02080

   Note:
   

   • Do not turn the A/C switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

   • Approximately 200 g (7.1 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

   Tip:

   Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an A/C system.

WARM UP ENGINE

1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

   Note:

   Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

INSPECT FOR REFRIGERANT LEAK

1. After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

2. Carry out the test under the following conditions:

   
   

   • Turn the engine switch off.

   • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

   • Repeat the test 2 or 3 times.

   • Make sure that there is some refrigerant remaining in the refrigeration system.

     When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)

3. 

   Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.

4. 

   Bring the halogen leak detector close to the drain hose with the detector's power off, and then turn the detector on.

   Tip:
   

   • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

   • Bring the halogen leak detector sensor under the drain hose.

   • When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.

5. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

INSPECT FOR COOLANT LEAK

1. Remove the radiator reservoir cap.

   CAUTION:

   Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

2. 

   Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.

3. Warm up the engine.

4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm², 17 psi), and then check that the pressure does not drop.

   If the pressure drops, check the hoses, radiator and water pump for leaks.

   If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

5. Reinstall the radiator reservoir cap.

INSTALL V-BANK COVER SUB-ASSEMBLY

1. 

   Fit the 3 retainers and install the V-bank cover sub-assembly.

INSPECT HOOD SUB-ASSEMBLY

1. 

   Check that the clearance measurements of areas A through H are within each standard range.

   Table 7. Text in Illustration

   *A

   for ALPHARD

   *B

   for VELLFIRE

   Standard Clearance
   Area Measurement Area Measurement A 5.9 to 9.9 mm (0.232 to 0.390 in.) E 2.2 to 6.2 mm (0.0866 to 0.244 in.) B 3.4 to 7.4 mm (0.134 to 0.291 in.) F 2.3 to 6.3 mm (0.0906 to 0.248 in.) C 2.3 to 5.3 mm (0.0906 to 0.209 in.) G 2.3 to 5.3 mm (0.0906 to 0.209 in.) D -1.4 to 1.6 mm (-0.0551 to 0.0630 in.) H -1.4 to 1.6 mm (-0.0551 to 0.0630 in.)

ADJUST HOOD SUB-ASSEMBLY

1. Horizontally and vertically adjust the hood.

   
   
   1. 

      Loosen the 4 hinge bolts of the hood.

   2. Adjust the clearance between the hood and front fender by moving the hood.

   3. Tighten the 4 hinge bolts after the adjustment.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

2. Adjust the height of the front end of the hood using the cushion rubbers.

   
   
   1. 

      Adjust the cushion rubbers so that the heights of the hood and fender are aligned.

      Tip:

      Raise or lower the front end of the hood by turning the cushion rubbers.

3. Adjust the hood lock.

   
   
   1. 

      Loosen the 3 bolts.

   2. Tighten the bolts after the adjustment.

      7.5 N*m

      77 kgf*cm

      66 in.*lbf

   3. Check that the striker can engage with the hood lock smoothly.